Documentos de Académico
Documentos de Profesional
Documentos de Cultura
water/wastewater
use and management
Operations
Best Practice
Series
2010
www.ipieca.org
The global oil and gas industry association for environmental and social issues
5th Floor, 209215 Blackfriars Road, London SE1 8NL, United Kingdom
Telephone: +44 (0)20 7633 2388 Facsimile: +44 (0)20 7633 2389
E-mail: info@ipieca.org Internet: www.ipieca.org
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the
prior consent of IPIECA.
This publication is printed on paper manufactured from fibre obtained from sustainably grown
softwood forests and bleached without any damage to the environment.
Petroleum refining
water/wastewater
use and management
IPIECA Operations Best Practice Series
This document was prepared by AECOM, Inc. on behalf of the IPIECA Refinery Water Management Task Force.
The assistance of M. Venkatesh of ENSRAECOM is gratefully acknowledged.
Cover photographs reproduced courtesy of the following (clockwise from top left): ExxonMobil; Nexen; Photodisc Inc.;
iStockphoto; Corbis; Shutterstock.com.
IPIECA
Contents
Introduction
Sources of water
25
Wastewater segregation
27
Primary treatment
28
29
Sour water
11
13
Spent caustic
14
16
18
18
Boiler blowdown
18
18
Unrecovered condensate
18
20
Equalization system
Location of the equalization system
Secondary treatment
30
31
31
31
35
Tertiary treatment
38
Sand filtration
38
Activated carbon
38
Chemical oxidation
39
Treatment of sludges
40
40
40
41
20
42
20
43
20
Fire water
43
21
43
21
Utility water
43
43
Miscellaneous dischargesminimization
Laboratory wastewater
Spent/unused hydrocarbons samples
best practices
21
21
43
44
Microfiltration or ultrafiltration
45
21
47
21
48
22
Ion exchange
48
22
50
50
Contaminated stormwater
22
Non-contaminated stormwater
23
Media filtration
51
24
Microfiltration or ultrafiltration
51
Sewerage management
ii
28
Condensate blowdown
25
Process water
Cooling water
25
Wastewater
Desalter effluent
Effluent treatment
52
Figure 11
25
Figure 12
26
53
Figure 13
26
Ion exchange
53
Figure 14
27
53
Figure 15
API separator
28
References
55
Figure 16
29
Figure 17
30
Figure 18
32
Figure 19
33
Figure 20
34
Figure 21
34
Figure 22
35
Figure 23
Trickling filters
36
Figure 24
36
Figure 25
Nitrification/denitrification system
37
Figure 26
Sand filtration
38
Figure 27
39
List of Tables
Table 1
Table 2
Table 3
Table 4
10
Table 5
12
Table 6
12
Table 7
14
Table 8
14
Figure 28
39
Table 9
18
Figure 29
40
Table 10
42
Figure 30
41
Table 11
50
Figure 31
41
Figure 32
44
Figure 33
Media filtration
45
Figure 34
Microfiltration or ultrafiltration
46
Figure 35
Microfiltration or ultrafiltration,
with reverse osmosis
47
Microfiltration or ultrafiltration,
with nanofiltration
48
List of Figures
Figure 1
Figure 2
Figure 3
11
Figure 4
13
Figure 5
16
Figure 37
49
Figure 6
17
Figure 38
Media filtration
51
Figure 7
18
Figure 39
Microfiltration/ultrafiltration
52
Figure 8
19
Figure 40
Figure 9
Boiler blowdowntypical
19
Microfiltration/ultrafiltration, plus
reverse osmosis
52
Figure 10
19
Microfiltration/ultrafiltration, plus
nanofiltration
53
53
Figure 36
Figure 41
Figure 42
IPIECA
Introduction
This manual describes typical best practices and
the refinery.
Introduction
refinerys discharge.
Wastewater
Effluent treatment
treatment systems.
balance in a refinery.
Sources of water
Surface water
Water to the refinery can be supplied from various
surface-water sources such as rivers or lakes. In some
cases it may also be supplied from the sea or from
other brackish water sources. Additional supply of
water can come from groundwater located in
aquifers, if the subsurface water is available and
accessible. Typical characteristics of raw water can
include varying amounts of solids and/or salts, also
referred to as total suspended solids (TSS), total
dissolved solids (TDS) and turbidity. Each water body
IPIECA
Source
Lake
River
Groundwater (wells)
Sea water
Purchased water
Water can also be supplied from a municipality.
Municipalities generally can offer potable water
(drinking water) but may also be able to offer a
treated effluent for industrial use or reuse. Potable
water (drinking water and sanitary water) required
by a refinery is frequently purchased from a local
municipality. If available, potable water may also
come from groundwater aquifers or alternative
sources.
Water in crude
When crude arrives at a refinery, it often carries
entrained water that remains from the oil well
extraction process and/or pickup during
transshipment. The water is typically removed as
storage tank bottom sediment and water (BS&W) or
in the desalter which is part of the crude unit in the
refinery, and is typically sent to wastewater treatment.
Rain
Another source of water for a refinery is rain. Rain
that falls within the refinery battery limits is typically
treated before discharge. Rain that falls in nonindustrial areas of a refinery, e.g. parking lots, green
4
Wastewater
Refineries can generate a significant amount of
wastewater that has been in contact with
hydrocarbons. Wastewater can also include water
rejected from boiler feedwater pretreatment processes
(or generated during regenerations). Wastewater can
also refer to cooling tower blowdown stream, or even
once-through cooling water that leaves the refinery.
Once-through cooling water typically does not
receive any treatment before discharge. Cooling
tower blowdown water and wastewater from raw
water treating may or may not receive treatment at
the wastewater treatment plant (WWTP) before
discharge. Contaminated wastewater is typically
sent to either a wastewater treatment plant that is
located at the facility, or it can be pretreated and
sent to the local publicly owned treatment works or
third-party treatment facility for further treatment.
Water that has not been in direct contact with
hydrocarbons or which has only minimal
contamination can be a source for reuse and is
discussed in the section on Recycle and reuse
Steam losses
Low pressure steam that is produced in the refinery
is vented to the atmosphere when it is in excess.
Other sources include tracing steam that is vented at
some locations in the refinery. Proper monitoring of
the steam system in the refinery will help minimize
the production of excess steam and minimize/
eliminate the need for venting. Any expected losses
should be considered when reviewing the water
balance in a refinery.
Water in product
There is some water that leaves with some of the
products in the refinery although this is a very small
amount because it is limited by product quality
specifications.
Process water
In refineries, water is typically used for various
purposes where the water is closely contacted with
the hydrocarbons. Softened water is usually used for
these purposes.
Boiler feedwater
The boiler feedwater (BFW) required for the
generation of steam in a refinery needs to be
treated prior to use. The higher the steam pressure
being generated, the higher the purity of the BFW
required. Ordinarily water is treated by the limesoda process and further purified by ion exchange
or by hot phosphate treatment in order to produce
boiler feedwater. Reverse osmosis can also be used
to soften the water.
5
IPIECA
Cooling water
Water-cooled condensers, product coolers (heat
exchangers) and other heat exchangers can use a
large amount of water in a refinery. Some refineries
use air coolers, where the process stream is
exchanged with air prior the being sent to a cooling
water heat exchanger. This will minimize the use of
cooling water in the refinery.
Some refineries use a once-through system where
Potable water
Potable water is required for use in kitchens, wash
areas and bathrooms in refineries as well as in
safety showers/eyewash stations. City water or
treated groundwater can be used for this purpose.
In remote locations or in small towns a portion of
the treated water from the plant softening unit may
be diverted for potable water use. The treated water
must be chlorinated to destroy bacteria, and then
pumped in an independent system to prevent
potential cross-contamination. Potable quality water
may also be required in some specialist chemical
operations (e.g. as a diluent).
Fire water
The requirements for fire water in refineries are
intermittent, but can constitute a very large flow.
Often, refineries collect stormwater from nonprocess areas and store it in a reservoir dedicated
to the fire water system in the plant.
areas.
Utility water
Utility water is used for miscellaneous washing
operations, such as cleaning an operating area. It
should be free from sediment but does not require
any other treatment.
remove them.
Problem
Removal methods
Turbidity
Hardness
Alkalinity
Sulphate
Demineralization, distillation
Chloride
Silica
Oil
Oxygen
Hydrogen sulphide
Conductivity
Dissolved solids
Suspended solids
IPIECA
Wastewater
This section describes the various sources of
Process water
Process water is defined as water that has been in
intimate contact with hydrocarbons in the refinery.
Water that is generated in the process units is
represented by the following categories:
desalter effluent;
sour water;
spent caustic.
Desalter effluent
Advantages
1. The water requires no or minimal pretreatment
Disadvantages
1. Increases overall water usage in the refinery
2. Increases generation of wastewater in the refinery
3. Increases capital and operating costs for
wastewater treatment
Recycled crude
tower overhead
Recycled vacuum
tower overhead
supplemented by
sources of water
Recycled stripped
sour water
IPIECA
10
Contaminant
400 to 1000
Free hydrocarbons
Up to 1000
Suspended solids
Up to 500
Phenol
10 to 100
Benzene
5 to 15
Sulphides
Up to 100
Ammonia
Up to 100
Sour water
are sent to the flare. The sour water from the drum
11
IPIECA
Producer
Typical destination
Comments
Crude
Atmospheric tower
overhead drum
Vacuum
Tower hotwell
Catalytic cracker
Fractionator overhead
drum
Delayed coker
Fractionator overhead
drum and blowdown drum
Visbreaker
Fractionator overhead
drum and blowdown drum
Hydrotreaters
Hydrocracker
Sulphur plant
none
600 to 1200
Free hydrocarbons
< 10
Suspended solids
< 10
Phenol
Up to 200
Benzene
Sulphides
< 10
Ammonia
< 100
12
crude tanks;
slop tanks.
13
IPIECA
Contaminant
400 to 1000
Free hydrocarbons
Up to 1000
Suspended solids
Up to 500
Sulphides
Up to 100
Spent caustic
Spent caustic is formed due to the extraction of
Intermediate product
Straight run LPG
H2S
RSH
Kerosene/jet fuel)
Phenol
HCN
Other
X
X
In-process abatement/minimization
best practices
The following in-process options have the common
objective of minimizing quantities of spent caustic
requiring disposal.
As discussed above, there are two types of
spent caustic that are generated in refineries
depending on the types of process units present.
Some refineries are able to treat the sulphidic
spent caustic in the refinery wastewater
treatment plant. Phenolic spent caustic is very
odorous and therefore cannot be treated in the
wastewater treatment plant. Phenolic spent
caustic (from catalytic cracker, coker and
kerosene/jet fuel treater) should be segregated
from the sulphidic spent caustic and stored
separately. This will allow the refinery to
properly evaluate appropriate strategies for
spent caustic disposal.
The amount of spent caustic generated is
dependent on operating procedures in the
treating units. These procedures often call for
the caustic to be purged when the sodium
hydroxide concentration in the solution reaches
a certain value. The production of spent caustic
can be minimized by exercising tighter control
of caustic treating operations by ensuring that
the caustic solution is not purged prematurely.
Hydrocarbons are normally treated in an amine
system to absorb the hydrogen sulphide prior to
being sent to a caustic treater. The operation of
the absorber should be reviewed to maximize
its efficiency of absorption so that the amount of
hydrogen sulphide reaching the caustic treating
system is minimized.
IPIECA
Cooling water
In refineries, crude oil is separated in various
fractions based on boiling point. This is
accomplished by fractional distillation of the crude
oil. The distillation is carried out in distillation
columns where the crude is heated up and
vapourized in a fuel (fuel oil, natural gas or refinery
fuel gas) fired heater. Various fractions are
separated by condensing and cooling products that
are withdrawn from the tower. From an overall heat
balance point of view, the heat that is put into the
system by burning fuel and/or the introduction of
steam has to be removed or rejected. This is
accomplished in various ways, including:
16
air coolers.
(typically 4 to 7).
IPIECA
Boiler blowdown
Contaminant
150
Free hydrocarbons
<5
Suspended solids
Up to 200
Dissolved solids
Up to 700
Unrecovered condensate
The drivers for condensate recovery in refineries
include:
Condensate blowdown
of the sewers.
18
19
IPIECA
Condensate blowdownbest
practices
local regulation.
Miscellaneous discharges
best practices
There are a variety of additional activities that, if
implemented routinely at a facility, could reduce
water use. Some of these activities include the
following:
20
leaks.
Miscellaneous discharges
minimization
Some additional ideas that can contribute to
minimization of wastewater discharges to the sewer:
of raw water.
Laboratory wastewater
categorized as follows:
laboratory.
Spent/unused hydrocarbons
samplesbest practices
The spent/unused hydrocarbon samples should be
disposed of in segregated drums located at
convenient locations inside the laboratory. These
21
IPIECA
washrooms.
Contaminated stormwater
Process area runoff (contaminated stormwater) can
be collected in storage tanks or impoundment basins
and discharged for wastewater treatment at a
controlled rate. This lowers the hydraulic loading on
22
of drain lines.
Non-contaminated stormwater
separator1
and the
23
IPIECA
Sewerage management
Sewerage refers to wastewater that is generated in
kitchens, locker rooms and washrooms in the
refinery. At many locations the sewerage is
combined with the wastewater generated in the
refinery and sent to the wastewater treatment plant.
Other refineries segregate the sewerage and treat it
separately from the refinery wastewater.
The strategy for treatment should be dictated by the
requirements of the local regulation. Typically the
flow of sewerage in a refinery is relatively small
when compared to the other wastewater generated
in the refinery. If local regulations require that the
combined treated wastewater needs to be
chlorinated prior to discharge then segregation and
separate treatment will result in substantial savings
in chlorination costs. Local regulations may dictate
additional certification and training for refinery
WWTP operators when sanitary waste is comingled
with refinery wastewater.
Treatment of sewerage can be effectively carried out
in small self-contained packaged treatment systems
at relatively small capital and operating costs.
24
Effluent treatment
This section discusses the various types of treatment
25
IPIECA
and an analysis indicates that it is more costeffective to install a separation step on the desalter
26
Wastewater segregation
Given that there is a shortage of available raw
water in many locations, and the fact that a typical
27
IPIECA
Primary treatment
removed periodically.
1.
2.
3.
4.
5.
6.
7.
8.
28
29
IPIECA
of suspension.
Equalization system
The objective of the equalization system is to
minimize or reduce the fluctuations caused due to
either sudden change of flow or composition in the
wastewater treatment plant.
30
Secondary treatment
Biological treatment is the most widely used wastewater
treatment technology for removal of dissolved
organic compounds in the oil refining industry.
In general, biological treatment can be classified
Activated sludge
An activated sludge process is the most effective of
all the biological systems available. It is used in
many refineries around the world and offers a
reliable method of biological treatment.
Activated sludge is a continuous suspension of
aerobic biological growths in a wastewater
containing entrapped suspended colloidal, dissolved
organic and inorganic materials. The
microorganisms use the organic material as a
carbon source and energy for the microbial growth,
and convert the food into cell tissue, water and
oxidized products (mainly CO2).
31
IPIECA
(WAS).
Figure 19.
32
cycle.
IPIECA
34
page 47).
Aerated lagoons
In this type of system, wastewater is treated in an
earthen in-ground basin that is used for both the
aeration and the settling functions. Air is injected
through mechanical or diffused aeration units into
the lagoon to promote biological treatment. There
are usually two types of aerated lagoons:
Aerobic lagoons: In aerobic lagoons, dissolved
oxygen is maintained throughout the basins. For
this type of a system, settling can take place at a
part of the pond separated by baffles or
separate sludge settling and disposal facilities
might be required. The settled sludge is removed
periodically.
Aerobic-anaerobic/facultative lagoons: In these
types of lagoons, oxygen is maintained in the
upper layer of the liquid in the basin and the rest
of the lagoon remains anaerobic. A portion of
suspended solids moves to the downstream part
of the lagoon where settling takes place and
undergoes anaerobic decomposition.
Figure 22 shows a typical lagoon treatment system.
sludge systems.
Trickling filters
The trickling filter system consists of:
a bed of packing material such as rock or plastic
packing on which the wastewater is distributed
continuously;
an underdrain system to carry the treated water
to other units; and
distributors for distributing the influent
wastewater to the surface of the filter bed.
35
IPIECA
36
Figure 24.
37
IPIECA
Tertiary treatment
Activated carbon
Removal of dissolved organic constituents from the
refinery wastewater can be done by carbon
adsorption. In general, activated carbon is usually
applied as an effluent polishing step (removal of
residual organics) for wastewater that has been
processed in a biological treatment system. This is
because the carbon usage will be prohibitively high
Sand filtration
Effluent from the biological treatment system
typically contains about 25 to 80 mg/l of
suspended solids depending on the operating
conditions in the clarifier. Refineries at many
locations need to meet limits as low as 15 mg/l on
a consistent basis. In these instances, one option is
for the effluent from the clarifier to be filtered using
sand filters. This process involves passing the
wastewater through a filter bed comprised of a filter
38
Chemical oxidation
hydrogen peroxide;
ozone.
information purposes.
39
IPIECA
Treatment of sludges
In a refinery wastewater treatment plant, sludge is
typically produced from the following unit operations:
40
land farming;
off-site disposal.
41
IPIECA
process water:
desalter makeup;
coker quench water;
FCC scrubbers;
hydrotreaters;
municipalities).
potable water;
down as follows:
utility water.
Contaminant specification
42
Re-use of non-contaminated
stormwater
Many opportunities exist for reuse of noncontaminated stormwater. Some examples of
applications for collected non-contaminated
stormwater runoff are described below.
Fire water
Fire drills and actual fire events at refineries require
large volumes of fire water. During emergencies,
firewater is usually drawn from an on-site storage
and supplemented by an outside source such as
rivers, lakes etc. Non-contaminated stormwater can
be directed to the fire pond in the refinery for
storage and reused in the fire water system as
required.
Utility water
Refinery utility water systems use non-potable, noncontaminated water. Utility water may be used for
any purpose in the refinery where water is needed,
such as paved area wash-down and wash water for
spill clean-ups. Stormwater may be collected and
pumped from storage into the plant utility water
supply header. As with any water reuse system, the
source of the water, its quality and potential
contaminants must be monitored and deemed
acceptable for all designated uses.
microfiltration or ultrafiltration;
IPIECA
and
wastewater reuse;
44
Microfiltration or ultrafiltration
used.
45
IPIECA
removed by backwashing.
membrane surfaces.
Microfiltration and ultrafiltration will both produce a
46
on-site or off-site.
47
IPIECA
Ion exchange
design.
48
osmosis followed by ion exchange is the most costeffective option for high purity water production.
backwash.
IPIECA
Technology summaryrefinery
wastewater reuse
50
Suitability
Media filtration
Removes suspended solids but not dissolved solids. Treated water not
suitable for cooling water or boiler feedwater makeup but can be
used for other uses such as utility water or fire water.
Ultrafiltration or microfiltration
Ion exchange
municipal wastewater:
infrastructure).
highlighted.
Media filtration
Microfiltration or ultrafiltration
IPIECA
Figure 39 Microfiltration/ultrafiltration
dioxide gas.
52
Ion exchange
53
IPIECA
54
References
Rase, Howard F., and Barrow, M.H., Project Engineering for Process Plants, John Wiley and Sons Inc.
Beychok, Milton R., Aqueous Wastes from Petroleum and Petrochemical Plants, John Wiley and Sons Inc.
Evans, Frank L. Jr., Equipment Design Handbook for Refineries and Chemical Plants, Volumes 1 and 2,
Gulf Publishing
Metcalf and Eddy, Wastewater Engineering Treatment and Reuse, 4th Edition, McGraw Hill
American Petroleum Institute, A Guide to Leak Detection for Above-Ground Storage Tanks, Publication 334,
First Edition, March 1996
American Petroleum Institute, Welded Tanks for Oil Storage, Downstream Segment, API Standard 650,
Eleventh Edition June 2007, Addendum 1 June 2008.
US DOE, Energy and Environmental Profile of the U.S. Petroleum Refining Industry, December 1998.
Environmental Protection Agency, Profile of the Petroleum Industry, EPA/310-R-95-013, 1995.
55
IPIECA is the global oil and gas industry association for environmental and social issues. It
develops, shares and promotes good practices and knowledge to help the industry improve its
environmental and social performance; and is the industrys principal channel of communication
with the United Nations.
Through its member led working groups and executive leadership, IPIECA brings together the
collective expertise of oil and gas companies and associations. Its unique position within the
industry enables its members to respond effectively to key environmental and social issues.
Association members
Company members
BG Group
OMV
BP
Petrobras
Chevron
Petronas
CNOOC
Petrotrin
ConocoPhillips
PTT EP
Eni
Qatargas
ExxonMobil
RasGas
Hess
Repsol YPF
Hunt Oil
Saudi Aramco
KPC
Shell
Mrsk
SNH
Marathon
StatoilHydro
Nexen
Talisman
NOC Libya
Total
Occidental
Woodside Energy
IPIECA
5th Floor, 209215 Blackfriars Road, London SE1 8NL, United Kingdom
Telephone: +44 (0)20 7633 2388 Facsimile: +44 (0)20 7633 2389
E-mail: info@ipieca.org Internet: www.ipieca.org
IPIECA 2010 All rights reserved.
www.ipieca.org